ICCM Conferences, The 14th International Conference of Computational Methods (ICCM2023)

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Whole process modeling of selective laser melting with a DEM-FVM-FEM coupled framework
Xu Zhou, Moubin Liu

Last modified: 2023-05-21

Abstract


As one of the most promising techniques of additive manufacturing technology, selective laser melting (SLM) has been widely used in many cutting-edge fields, such as aerospace, biomedical engineering, fiber-reinforced composites, and polymers [1]. However, it is noteworthy that defects such as gas pores, distortion, and micro-crack are easily generated during the SLM process, which are related to powder laying, melting, solidification, and subsequent residual stress generation. Due to simulating different stages of SLM needing different methods and huge challenges of effectively and accurately transmitting information between different stages, few existing simulation frameworks can couple and simulate the whole process of SLM. In this work, we propose a multiphase, multi-physics, multi-layer simulation framework to reproduce the whole process of SLM from powder laying to powder melting [2], to residual stress generation. In this simulation framework, the computational fluid dynamics-discrete element method (CFD-DEM) is used to simulate powder laying, the finite volume method (FVM) is coupled to simulate powder melting and flowing, and the finite element method (FEM) is used to simulate residual stress field. Information transmission between different stages is carried out through custom scripts and stereolithography (STL) files. Moreover, a sharp surface capturing technique (isoAdvector) and ray tracing heat source model [3] are coupled to improve simulation accuracy. This new framework can help to guide the design and optimization of SLM in the future.


Keywords


modeling; simulation; numerical methods

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